Heat deflection/high strength panel compositions

ABSTRACT

The following disclosure provides a structural mat for manufacturing a moldable structural hardboard body. The structural mat has a nucleated/coupled binder and a fibrous material. The nucleated/coupled binder material has a first binder material combined with a nucleating agent; and a second binder material combined with a coupling agent. The first binder material is combined with the nucleating agent to make a discrete nucleated/binder material. The second binder material is combined with the coupling agent to make a discrete coupled/binder material. The discrete nucleated/binder material and the discrete coupled/binder material are blended together. The fibrous material is blended with the discrete nucleated/binder material and the discrete coupled/binder material to form the structural mat.

RELATED APPLICATIONS

The present application claims priority to U.S. Patent Application No.60/637019, filed Dec. 17, 2004, entitled Heat Deflection/High StrengthPanel Compositions. The present application is also aContinuation-in-Part of U.S. patent application Ser. No. 10/287,250,filed on Nov. 4, 2002, which is related to and claims priority to thefollowing U.S. Provisional Patent Applications Ser. No. 60/347,858,filed on Nov. 7, 2001, entitled Laminated Panels and Processes; Ser. No.60/349,541, filed on Jan. 18, 2002, entitled Truss Panel; Ser. No.60/358,857, filed on Feb. 22, 2002, entitled Compression Molded Visor;Ser. No. 60/359,017, filed on Feb. 22, 2002, entitled Assemblies andTooling for Work Surfaces; Ser. No. 60/359,602, filed on Feb. 26, 2002,entitled Compression Molded Visor, and Ser. No. 60/400,173, filed onJul. 31, 2002, entitled Composite Material. To the extent not includedbelow, the subject matter disclosed in these applications is herebyexpressly incorporated into the present application.

TECHNICAL FIELD

The present disclosure relates to fiber mats, boards, panels, laminatedcomposites, uses and structures, and processes of making the same. Moreparticularly, a portion of the present disclosure is related to highstrength and high heat deflection structural mats and resultinghardbound panels.

BACKGROUND AND SUMMARY

Industry is consistently moving away from wood and metal structuralmembers and panels, particularly in the vehicle manufacturing industry.Such wood and metal structural members and panels have high weight tostrength ratios. In other words, the higher the strength of the wood andmetal structural members and panels, the higher the weight. Theresulting demand for alternative material structural members and panelshas, thus, risen proportionately. Because of their low weight tostrength ratios, as well as their corrosion resistance, suchnon-metallic panels have become particularly useful as structuralmembers in the vehicle manufacturing industry as well as officestructures industry, for example.

Often such non-metallic materials are in the form of compositestructures or panels which are moldable into three-dimensional shapesfor use in any variety of purposes. It would, thus, be beneficial toprovide a composite material structure that has high strength usingoriented and/or non-oriented fibers with bonding agents havingcompatible chemistries to provide a strong bond across the composite'slayers. It would be further beneficial to provide a manufacturing andfinish coating process for such structures in some embodiments.

It will be appreciated that the prior art includes many types oflaminated composite panels and manufacturing processes for the same.U.S. Pat. No. 4,539,253, filed on Mar. 30, 1984, entitled High ImpactStrength Fiber Resin Matrix Composites, U.S. Pat. No. 5,141,804, filedon May 22, 1990, entitled Interleaf Layer Fiber Reinforced ResinLaminate Composites, U.S. Pat. No. 6,180,206 B1, filed on Sep. 14, 1998,entitled Composite Honeycomb Sandwich Panel for Fixed Leading Edges,U.S. Pat. No. 5,708,925, filed on May 10, 1996, entitled Multi-LayeredPanel Having a Core Including Natural Fibers and Method of Producing theSame, U.S. Pat. No. 4,353,947, filed Oct. 5, 1981, entitled LaminatedComposite Structure and Method of Manufacture, U.S. Pat. No. 5,258,087,filed on Mar. 13, 1992, entitled Method of Making a Composite Structure,U.S. Pat. No. 5,503,903, filed on Sep. 16, 1993, entitled AutomotiveHeadliner Panel and Method of Making Same, U.S. Pat. No. 5,141,583,filed on Nov. 14, 1991, entitled Method of and Apparatus forContinuously Fabricating Laminates, U.S. Pat. No. 4,466,847, filed onMay 6, 1983, entitled Method for the Continuous Production of Laminates,and U.S. Pat. No. 5,486,256, filed on May 17, 1994, entitled Method ofMaking a Headliner and the Like, are all incorporated herein byreference to establish the nature and characteristics of such laminatedcomposite panels and manufacturing processes herein.

A portion of the following disclosure is related to high strength highheat deflection panels. Illustratively, random or woven fibers can bebonded and formed into a panel or mat using a combination of nucleatedand coupled polypropylene. The nucleating agent may provide increasedheat deflection and the coupling agent may provide high strength to thefiber panel. Other embodiments of the present disclosure may include afiber panel comprising natural and/or synthetic fibers bonded togetherusing nucleated polypropylene. An alternative embodiment includes anatural and/or synthetic fiber panel comprising a coupling agent andpolypropylene to bind the fibers together.

The following disclosure further provides a structural mat formanufacturing a moldable structural hardboard panel. The structural matcomprises a nucleated/coupled binder and a fibrous material. Thenucleated/coupled binder material comprises: a first binder materialcombined with a nucleating agent; and a second binder material combinedwith a coupling agent. The first binder material is combined with thenucleating agent to make a discrete nucleated/binder material. Thesecond binder material is combined with the coupling agent to make adiscrete coupled/binder material.

The discrete nucleated/binder material and the discrete coupled/bindermaterial are blended together. The fibrous material is blended with thediscrete nucleated/binder material and the discrete coupled/bindermaterial to form the structural mat.

In the above and other illustrative embodiments, the structural mat mayfurther comprise: the first and second binder materials each beingpolypropylene; both the discrete nucleated/binder material and thediscrete coupled/binder material are in fibrous form; the first bindermaterial combined with the nucleating agent further comprises about 4%nucleating agent with the balance being the first binder material; thesecond binder material combined with the coupling agent furthercomprises about 5% coupling agent with the balance being the firstbinder material; the mat comprises about 25% discrete nucleated/bindermaterial; the mat comprises about 25% discrete coupled/binder material;the mat comprises about 50% fibrous material; the mat comprises about25% discrete nucleated/binder material with about 2% of the structuralmat being the nucleating agent, about 25% discrete coupled/bindermaterial with about 2.5% of the structural mat being the coupling agent,and about 50% fibrous material; the nucleating agent being analuminosilicate glass; the coupling agent being maleic anhydride; thediscrete nucleated/binder material and the discrete coupled/bindermaterial are blended homogeneously; the fibrous material being arandomly-oriented fibrous material; the randomly-oriented fibrousmaterial being a natural fiber material; and the fibrous material beinga woven material.

Another illustrative embodiment of the present disclosure provides astructural panel having high strength and high heat deflectionproperties. The panel comprises a rigid body comprised of solidifiednucleated/coupled binder material and fibrous material. Both materialsare dispersed throughout the thickness of the body. The solidifiednucleated/coupled binder is formulated from a nucleated material with abinder, and a coupled material with a binder.

In the above and other illustrative embodiments, the structural panelmay further comprise: the nucleated/coupled binder material comprisingpolypropylene; about 50% nucleated/coupled polypropylene which comprisesabout 4% nucleating agent and about 5% coupling agent, and about 50%fibrous material; the nucleating agent being an aluminosilicate glass;the coupling agent being maleic anhydride; the fibrous material being arandomly-oriented fibrous material; the randomly-oriented fibrousmaterial being a natural fiber material; the fibrous material is a wovenmaterial; the nucleated/coupled polypropylene being in a concentrationfrom about 40% to 50%; the fibrous material being in a concentrationfrom about 50% to 60%.

Another illustrative embodiment of the present disclosure provides amethod of making a structural mat for manufacturing a moldablestructural hardboard panel. The method comprising the steps of:combining a nucleating agent with a first polypropylene material;forming a solid fibrous combination of nucleating agent and firstpolypropylene material; combining a coupling agent with a secondpolypropylene material, separate from the blended nucleating agent andfirst polypropylene material; forming a solid fibrous combination ofcoupling agent and second polypropylene material; blending the solidfibrous combination of nucleating agent and first polypropylene materialwith the solid fibrous combination of coupling agent and secondpolypropylene material; blending a fiber material with the blended solidfibrous combination of nucleating agent and first polypropylene materialand solid fibrous combination of coupling agent and second polypropylenematerial; and forming a structural mat by combination of the fibermaterial with blended solid fibrous combination of nucleating agent andfirst polypropylene material and solid fibrous combination of couplingagent and second polypropylene material.

In the above and other illustrative embodiments, the method may furthercomprise the steps of: formulating the nucleating agent and firstpolypropylene material with about 4% nucleating agent and the balancebeing the first polypropylene material;

formulating the coupling agent and second polypropylene material withabout 5% coupling agent and the balance being the second polypropylenematerial; providing about 25% nucleating agent and first polypropylenematerial; providing about 25% coupling agent and second polypropylenematerial; providing about 50% fibrous material;

providing about 25% nucleating agent and first polypropylene materialwith about 2% of the structural mat being the nucleating agent, about25% coupling agent and second polypropylene material with about 2.5% ofthe structural mat being the coupling agent, and about 50% fibrousmaterial; blending the nucleating agent and first polypropylene materialand the coupling agent and second polypropylene material homogeneously;providing the nucleating agent and first polypropylene material and thecoupling agent and second polypropylene material in a concentration fromabout 40% to 50%; providing the fibrous material in a concentration fromabout 50% to 60%; heating the structural mat to at least the melttemperature of the first and second polypropylene material; assertingpressure to the structural mat; and forming a hardboard body from themat.

Additional features and advantages of this disclosure will becomeapparent to those skilled in the art upon consideration of the followingdetailed description of illustrated embodiments exemplifying the bestmode of carrying out such embodiments as presently perceived.

BRIEF DESCRIPTION OF DRAWINGS

The present disclosure will be described hereafter with reference to theattached drawings which are given as non-limiting examples only, inwhich:

FIG. 1 is an exploded side view of a laminated hardboard panel;

FIG. 2 is a side view of the laminated hardboard panel of FIG. 1 in anillustrative-shaped configuration;

FIG. 3 is a perspective view of a portion of the laminated hardboardpanel of FIG. 1 showing partially-pealed plies of woven and non-wovenmaterial layers;

FIG. 4 is another embodiment of a laminated hardboard panel;

FIG. 5 is another embodiment of a laminated hardboard panel;

FIG. 6 is another embodiment of a laminated hardboard panel;

FIG. 7 is a perspective view of a honeycomb core laminated panel;

FIG. 8 is a top, exploded view of the honeycomb section of the panel ofFIG. 7;

FIG. 9 is a perspective view of a portion of the honeycomb section ofthe panel of FIG. 7;

FIG. 10 is a perspective view of a truss core laminated panel;

FIG. 11 a is a side view of an illustrative hinged visor body in theopen position;

FIG. 11 b is a detail view of the hinge portion of the visor body ofFIG. 11 a;

FIG. 12 a is a side view of an illustrative hinged visor body in thefolded position;

FIG. 12 b is a detail view of the hinge portion of the visor body ofFIG. 12 a;

FIG. 13 is an end view of a die assembly to compression mold a fibermaterial body and hinge;

FIG. 14 a is a top view of the visor body of FIGS. 11 and 12 in the openposition;

FIG. 14 b is an illustrative visor attachment rod;

FIG. 15 is a perspective view of a wall panel comprising a laminatedpanel body;

FIG. 16 is a work body;

FIG. 17 is a sectional end view of a portion of the work body of FIG. 16showing an illustrative connection between first and second portions;

FIG. 18 is a sectional end view of a portion of the work body of FIG. 16showing another illustrative connection between first and secondportions;

FIG. 19 is a sectional end view of a portion of the work body of FIG. 16showing another illustrative connection between first and secondportions;

FIG. 20 is a side view of a hardboard manufacturing line;

FIG. 21 a is a top view of the hardboard manufacturing line of FIG. 20;

FIG. 22 is a side view of the uncoiling and mating stages of thehardboard manufacturing line of FIG. 20;

FIG. 23 is a side view of the pre-heating stage of the hardboardmanufacturing line of FIG. 20;

FIG. 24 is a side view of the heat, press and cooling stages of thehardboard manufacturing line of FIG. 20;

FIG. 25 is a side view of a laminating station and shear and trim stagesas well as a finishing stage of the hardboard manufacturing line of FIG.20;

FIG. 26 is a top view of the laminating station and shear and trimstages as well as the finishing stage of the hardboard manufacturingline of FIG. 20;

FIG. 27 is a side view of a portion of the laminating station stage ofthe hardboard manufacturing line of FIG. 20;

FIG. 28 is another top view of the shear and trim stages as well as thefinishing stage of the hardboard manufacturing line of FIG. 20;

FIG. 29 is a top view of another embodiment of a laminated hardboardmanufacturing line;

FIG. 30 is a side view of the calendaring stage of the hardboardmanufacturing line of FIG. 29;

FIG. 31 is a diagrammatic and side view of a portion of a materialsrecycling system;

FIG. 32 is a side view of a materials recycling system and laminatedhardboard manufacturing line;

FIG. 33 is a top view of the materials recycling system and laminatedhardboard manufacturing line of FIGS. 31 and 32;

FIG. 34 is a mechanical properties chart comparing the tensile andflexural strength of an illustrative laminated hardboard panel withindustry standards;

FIG. 35 is a mechanical properties chart comparing the flexural modulusof an illustrative laminated hardboard panel with industry standards;

FIGS. a through c 36 are sectional views of the fibrous material layersubjected to various amounts of heat and pressure; and

FIG. 37 is a chart showing an illustrative manufacturing process for astructural mat comprising nucleated and coupled polypropylene.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplification set out hereinillustrates several embodiments, and such exemplification is not to beconstrued as limiting the scope of this disclosure in any manner.

DETAILED DESCRIPTION OF THE DRAWINGS

An exploded side view of a laminated composite hardboard panel 2 isshown in FIG. 1. Hardboard panel 2 illustratively comprises a fasciacover stock 4 positioned as the surface layer of panel 2. Fascia coverstock 4 may be comprised of fabric, vinyl, leathers, acrylic, epoxies,or polymers, etc. It is appreciated, however, that hardboard panel 2 mayinclude, or not include, such a fascia cover.

The laminated composite hardboard panel 2 illustratively comprises afirst sheet of fibrous material layer 6. Fibrous material layer 6illustratively comprises a natural fiber, illustratively about 25 weightpercent hemp and about 25 weight percent kenaf with the balance beingillustratively polypropylene. The fibers are randomly oriented toprovide a nonspecific orientation of strength. Variations of thisfibrous material are contemplated including about 24.75 weight percenthemp and about 24.75 weight percent kenaf combination with about 50weight percent polypropylene and about 0.05 weight percent maleicanhydride. Other such fibrous materials can be used as well, such asflax and jute. It is also contemplated that other blend ratios of thefibrous material can be used to provide a nonspecific orientation ofstrength. It is further contemplated that other binders in place ofpolypropylene may also be used for the purpose discussed further herein.Furthermore, it is contemplated that other fibrous materials which havehigh process temperatures in excess of about 400 degrees F., forexample, may be used as well.

A woven fiber layer 8 illustratively comprises a woven glass with apolypropylene binder, and is illustratively located between the fibrousmaterial layers 6.

It is appreciated that other such woven, non-metal fiber materials maybe used in place of glass, including nylon, Kevlar, fleece and othernatural or synthetic fibers. Such woven fiber provides bi-directionalstrength. In contrast, the fibrous material layers 6 providenonspecific-directional strength, thus giving the resulting compositeenhanced multi-directional strength.

Each surface 10 of fibrous material layers 6 that is adjacent to wovenmaterial layer 8 bonds to surfaces 12 of layer 8. A bond is createdbetween fibrous material layer 6 and woven material layer 8 by a hightemperature melt and pressure process as discussed further herein.Because the glass and fibrous layers have compatible binders (i.e., thepolypropylene, or comparable binder), layers 6, 8 will melt and bind,forming an amalgamated bond between the same. Layers 6, 8 havingpolypropylene as a common chain in each of their respective chemistriesmakes the layers compatible and amenable to such three-dimensionalmolding, for example.

It is appreciated that panel 2 may comprise a plurality of fibrousmaterial layers 6, with woven material layers 8 laminated between eachpair of adjacent surfaces 10 and 12, respectively. A pealed view ofhardboard panel 2, shown in FIG. 3, illustrates such combined use ofwoven and nonspecific-directional or randomly-oriented fibers. Therandom fibers 14 make up fibrous material layer 6, whereas the wovenfibers 16 make up the fiber layer 8. Because bulk mass can increase thestrength of the panel, it is contemplated that more alternating fibrousand woven fiber layers used in the laminated composite will increase thestrength of the panel. The number of layers used, and which layer(s)will be the exterior layer(s), can be varied, and is often dictated bythe requirements of the particular application.

Testing was conducted on illustrative hardboard panels to demonstratetensile and flexural strength. The hardboard laminated materialconsisted of a first layer of 600 gram 80 percent polypropylene 20percent polyester fleece, a second layer of 650 gram fiberglass mix (75percent 0.75 K glass/25 percent polypropylene and 10 percent maleicanhydride), a third layer 1800 gram 25 percent hemp/25 percent kenafwith 5 percent maleic anhydride and the balance polypropylene, a fourthlayer of the 650 g fiberglass mix, and a fifth layer of the 600 g 80percent polypropylene 20 percent polyester fleece. This resulted in anapproximate 4300 gram total weight hardboard panel.

The final panel was formed by subjecting it to a 392 degrees F. ovenwith a 6 millimeter gap and heated for about 400 seconds. The materialwas then pressed using a 4.0 millimeter gap. The final composite panelresulted in an approximate final thickness of 4.30 millimeter.

To determine such panel's tensile and flexural properties, ASTM D 638-00and ASTM D790-00 were used as guidelines. The panel samples' shape andsize conformed to the specification outlined in the standards as closelyas possible, but that the sample thickness varied slightly, as notedabove. A Tinius Olson Universal testing machine using industry specificfixtures was used to carry out the tests.

Two lauan boards were coated with a gelcoat finish and formed into final2.7 millimeter and 3.5 millimeter thickness boards, respectively. Theseboards were used as a baseline for comparison with the hardboard panelof the present disclosure. Each of the samples were then cut to theshape and sizes pursuant the above standards. The tensile and flexuralproperties of the lauan boards were determined in the same manner as thehardboard panel above. Once the results were obtained they were thencharted against the results of the hardboard panel for comparison, asshown below and in FIGS. 34 and 35. The results herein represent theaverage over 10 tested samples of each board. Avg. Tensile Avg. FlexuralAvg. Flexural Panel Description Strength - psi Strength - psi Modulus -psi Hardboard panel 8,585 14,228 524,500 Industry standard - 5,883 9,6801,045,700 FRP/2.7 mm lauan Industry standard - 7,900 8,260 624,800FRP/3.5 mm lauan

As depicted by FIG. 2, laminated panel 2 can be formed into any desiredshape by methods known to those skilled in the art. It is appreciatedthat the three-dimensional molding characteristics of several fibroussheets in combination with the structural support and strengthcharacteristics of glass/polypropylene weave materials located betweenpairs of the fibrous sheets will produce a laminated composite materialthat is highly three-dimensionally moldable while maintaining hightensile and flexural strengths. Such a laminated panel is useful for themolding of structural wall panel systems, structural automotive parts,highway trailer side wall panels (exterior and interior), recreationalvehicle side wall panels (exterior and interior), automotive andbuilding construction load floors, roof systems, modular constructedwall systems, and other such moldable parts. Such a panel may replacestyrene-based chemical set polymers, metal, tree cut lumber, and othersimilar materials. It is believed that such a moldable laminated panelcan reduce part cost, improve air quality with reduced use of styrene,and reduce part weight. Such a panel may also be recyclable, therebygiving the material a presence of sustainability.

Another embodiment of a hardboard panel 20 is shown in FIG. 4. Thispanel 20 comprises a fibrous material layer 6 serving as the core, andis bounded by fiberglass layers 22 and fleece layers 24, as shown. Forexample, the fibrous material layer 6 may comprise the conventionalnon-oriented fiber/polypropylene mix as previously discussed, atillustratively 1800 or 2400 g weights. The fiberglass layer comprises a50 weight percent polypropylene/about 50 weight percent maleicpolypropylene (illustratively 400 g/m²) mix. The fleece layer comprisesan about 50 weight percent polypropylene/about 50 weight percentpolyester (illustratively 300 g/m²) mix. The fleece material providesgood adhesion with the polypropylene and is water-proof at ambientconditions. Furthermore, the polyester is a compatible partner with thepolypropylene because it has a higher melt temperature than thepolypropylene. This means the polypropylene can melt and bond with theother layer without adversely affecting the polyester. In addition, themaleic anhydride is an effective stiffening agent having high tensileand flexural strength which increases overall strength of the panel.

It is contemplated that the scope of the invention herein is not limitedonly to the aforementioned quantities, weights and ratio mixes ofmaterial and binder. For example, the fleece layer 24 may comprise anabout 80 weight percent polypropylene/about 20 weight percent polyester(illustratively 600 g/m²) mix. The laminated composite panel 20 shown inFIG. 4 may include, for example, both fleece layers 24 comprising the50/50 polypropylene/polyester mix, or one layer 24 comprising the 50/50polypropylene/polyester mix, or the 80/20 polypropylene/polyester mix.In addition, same as panel 2, the binder used for panel 20 can be anysuitable binder such as polypropylene, for example.

Another embodiment of a laminated hardboard panel 28 is shown in FIG. 5.This panel 28 comprises a fibrous material layer 6 serving as the corewhich is bounded by fleece layers 24, as shown. As with panel 20, thefibrous material layer 6 of panel 28 may comprise the conventional,non-oriented fiber/polypropylene mix as previously discussed, atillustratively 1800 or 2400 g weights. Each fleece layer 24 may comprisean about 50 weight percent polypropylene/about 50 weight percentpolyester (illustratively 300 g/m²) mix, or may alternatively be anabout 80 weight percent polypropylene/about 20 weight percent polyester(illustratively 600 g/m²) mix. Or, still alternatively, one fleece layer24 may be the 50/50 mix and the other fleece layer 24 may be the 80/20mix, for example.

Another embodiment of a laminated hardboard panel 30 is shown in FIG. 6.This panel 30, similar to panel 20 shown in FIG. 4, comprises a fibrousmaterial layer 6 serving as the core which is bounded by fiberglasslayers 22 and fleece layers 24. The formulations for and variations ofthe fleece layer 24, the fiberglass layers 22 and the fibrous materiallayer 6 may comprise the formulations described in the embodiment ofpanel 20 shown in FIG. 4. Laminated panel 30 further comprises acalendared surface 32, and illustratively, a prime painted or coatedsurface 34. The calendaring process assists in making a Class A finishfor automobile bodies. A Class A finish is a finish that can be exposedto weather elements and still maintain its aesthetics and quality. Forexample, an embodiment of the coated surface 34 contemplated herein isdesigned to satisfy the General Motors Engineering standard for exteriorpaint performance: GM4388M, rev. June 2001. The process for applying thepainted or coated finish is described with reference to the calendaringprocess further herein below.

Further illustrative embodiment of the present disclosure provides amoldable panel material, for use as a headliner, for example, comprisingthe following constituents by weight percentage:

-   -   about 10 weight percent polypropylene fibers consisting of        polypropylene (about 95 weight percent) coupled with maleic        anhydride (about 5 weight percent), though it is contemplated        that other couplers may work as well; about 15 weight percent        kenaf (or similar fibers such as hemp, flax, jute, etc.) fiber        pre-treated with an anti-fungal/anti-microbial agent containing        about 2 weight percent active ingredient; wherein the fibers may        be pre-treated off-line prior to blending;    -   about 45 weight percent bi-component (about 4 denier) polyester        fiber; wherein the bi-component blend ratio is about 22.5 weight        percent high melt (about 440 degrees F.) polyester and about        22.5 weight percent low melt polyester (about 240 to about 300        degrees F. which is slightly below full melt temperature of        polypropylene to permit control of polypropylene movement during        heat phase); wherein, alternatively, like fibers of similar        chemistry may also be used; and    -   about 30 weight percent single component polyester fiber (about        15 denier) high melt (about 440 degrees F.); wherein,        alternatively, like fibers of similar chemistry may be used.

Again, such a material can be used as a headliner. This is because theformulation has a higher heat deflection created by stable fibers andhigh melt polypropylene, and by polyester and the cross-linked polymerto the polymer of the fibers. Furthermore, coupled polypropylene hascross-linked with non-compatible polyester low melt to form a commonmelt combined polymer demonstrating higher heat deflection ranges. Theanti-fungal treated natural fiber protects any cellulous in the fiberfrom colonizing molds for the life of the product should the head linerbe exposed to high moisture conditions.

It is appreciated that other formulations can work as well. For example,another illustrative embodiment may comprise about 40 percentbi-component fiber with 180 degree C. melt temperature, about 25 percentsingle component PET-15 denier; about 15 percent G3015 polypropylene andabout 20 percent fine grade natural fiber. Another illustrativeembodiment may comprise about 45 percent bi-component fibersemi-crystalline 170 degree C. melt temperature, about 20 percent singlecomponent PET-15 denier, about 15 percent low melt flow (10-12 mfi)polypropylene and about 20 percent fine grade natural fiber. It isfurther contemplated that such compositions disclosed herein may defineapproximate boundaries of usable formulation ranges of each of theconstituent materials.

A cutaway view of a honeycomb composite panel 40 is shown in FIG. 7.

The illustrated embodiment comprises top and bottom panels, 42, 44, witha honeycomb core 46 located there between. One illustrative embodimentprovides for a polypropylene honeycomb core sandwiched between twopanels made from a randomly-oriented fibrous material. The fibrousmaterial is illustratively about 30 weight percent fiber and about 70weight percent polypropylene. The fiber material is illustrativelycomprised of about 50 weight percent kenaf and about 50 weight percenthemp. It is contemplated, however, that any hemp-like fiber, such asflax or other cellulose-based fiber, may be used in place of the hemp orthe kenaf. In addition, such materials can be blended at any othersuitable blend ratio to create such suitable panels.

In one illustrative embodiment, each panel 42, 44 are heat-compressedinto the honeycomb core 46. The higher polypropylene content used in thepanels provides for more thermal plastic available for creating a meltbond between the panels and the honeycomb core. During the manufacturingof such panels 40, the heat is applied to the inner surfaces 48, 50 ofpanels 42, 44, respectively. The heat melts the polypropylene on thesurfaces which can then bond to the polypropylene material that makes upthe honeycomb core. It is appreciated, however, that other ratios offiber to polypropylene or other bonding materials can be used, so longas a bond can be created between the panels and the core. In addition,other bonding materials, such as an adhesive, can be used in place ofpolypropylene for either or both the panels and the core, so long as thechemistries between the bonding materials between the panels and thecore are compatible to create a sufficient bond.

A top detail view of the one illustrative embodiment of honeycomb core46 is shown in FIG. 8. This illustrative embodiment comprisesindividually formed bonded ribbons 52. Each ribbon 52 is formed in anillustrative battlement-like shape having alternating merlons 54 andcrenellations 56. Each of the corners 58, 60 of each merlon 54 isillustratively thermally-bonded to each corresponding corner 62, 64,respectively, of each crenellation 56. Such bonds 66 whichillustratively run the length of the corners are shown in FIG. 9.Successive rows of such formed and bonded ribbons 52 will produce thehoneycomb structure, as shown.

Another embodiment of the honeycomb composite panel comprises a fibrousmaterial honeycomb core in place of the polypropylene honeycomb core.

Illustratively, the fibrous material honeycomb core may comprise about70 weight percent polypropylene with about 30 weight percent fiber, forexample, similar to that used for top and bottom panels 42, 44,previously discussed, or even a 50/50 weight percent mix. Suchformulations are illustrative only, and other formulations that producea high strength board are also contemplated herein.

A perspective view of a truss composite 70 is shown in FIG. 10. Trusspanel composite 70 is a light weight, high strength panel for use ineither two- or three-dimensional body panel applications. Theillustrated embodiment of truss composite 70 comprises upper and lowerlayers 72, 74, respectively, which sandwich truss member core 76. Eachof the layers 72, 74, 76 is made from a combinationfibrous/polypropylene material, similar to that described in foregoingembodiments. Each layer 72, 74, 76 comprises a non-directional fibrousmaterial, illustratively, about 25 weight percent hemp and about 25weight percent kenaf with the balance being polypropylene. The fibersare randomly oriented to provide a non-specific orientation of strength.Illustrative variations of this fibrous material are contemplated, whichmay include, for example, an approximately 24.75 weight percent hemp and24.75 weight percent kenaf combination with 50 weight percentpolypropylene and 0.05 weight percent maleic anhydride. Other ratios offibrous materials, however, are also contemplated to be within the scopeof the invention. In addition, other fibrous materials themselves arecontemplated to be within the scope of the invention. Such materials maybe flax, jute, or other like fibers that can be blended in variousratios, for example. Additionally, it is appreciated that other bindersin place of polypropylene may also be used to accomplish the utilitycontemplated herein.

The truss core 76 is illustratively formed with a plurality of angledsupport portions 78, 80 for beneficial load support and distribution. Inthe illustrated embodiment, support portion 78 is oriented at ashallower angle relative to upper and lower layers 72, 74, respectively,than support portion 80 which is oriented at a steeper angle. It isappreciated that such support portions can be formed by using a stampingdie, continuous forming tool, or other like method. It is furtherappreciated that the thickness of any of the layers 72, 74, or even thetruss core 76 can be adjusted to accommodate any variety of loadrequirements. In addition, the separation between layers 72, 74 can alsobe increased or decreased to affect its load strength.

Between each support portion is an alternating contact portion, either82, 84. The exterior surface of each of the alternating contact portions82, 84 is configured to bond to one of the inner surfaces 86, 88 oflayers 72, 74, respectively. To create the bond between layers 72, 74and truss core 76, superficial surface heat, about 450 degrees F. forpolypropylene, is applied to the contact surfaces to melt the surfacelayer of polypropylene, similar to the process discussed further herein.At this temperature, the polypropylene or other binder material ismelted sufficiently to bond same with the polypropylene of the core. Inthis illustrative embodiment, contact portion 82 bonds to the surface 86of upper layer 72, and contact portion 84 bonds to the surface 88 oflayer 74. Once solidified, a complete bond will be formed without theneed for an additional adhesive. It is appreciated, however, that anadhesive may be used in place of surface heat bonding.

The outer surfaces of layers 72, 74 may be configured to accommodate afascia cover stock (not shown). Such fascia cover stock may be comprisedof fabric, vinyl, acrylic, leathers, epoxies, or polymers, paint, etc.In addition, the surfaces of layer 72, 74 may be treated with polyesterto waterproof the panel.

An end view of a hinged visor body 90 is shown in FIG. 11 a. Thisdisclosure illustrates a visor, similar to a sun visor used in anautomobile. It is appreciated, however, that such a visor body 90 isdisclosed herein for illustrative purposes, and it is contemplated thatthe visor does not represent the only application of a formed hingedbody. It is contemplated that such is applicable to any otherapplication that requires an appropriate hinged body.

In the illustrated embodiment, body 90 comprises body portions 92, 94and a hinge 96 positioned therebetween. (See FIGS. 11 b and 12 b.) Body90 is illustratively made from a low density fibrous material, asfurther described herein below. In one embodiment, the fibrous materialmay comprise a randomly-oriented fiber, illustratively about 50 weightpercent fiber-like hemp or kenaf with about 50 weight percentpolypropylene. The material is subjected to hot air and to variablecompression zones to produce the desired structure. (See further, FIG.13.) Another illustrative embodiment comprises about 25 weight percenthemp and about 25 weight percent kenaf with the balance beingpolypropylene. Again, all of the fibers are randomly oriented to providea non-specific orientation of strength. Other variations of thiscomposition are contemplated including, but not limited to, about a24.75 weight percent hemp and about a 24.75 weight percent kenafcombination with about 50 weight percent polypropylene and about 0.05weight percent maleic anhydride. Additionally, other fibrous materialsare contemplated to be within the scope of this disclosure, such as flaxand jute in various ratios, as well as the fibers in various other blendratios. It is also appreciated that other binders in place ofpolypropylene may also be used for the utility discussed herein.

The illustrated embodiment of body 90 comprises hinge portion 96allowing adjacent body portions 92, 94 to move relative to each other.The illustrative embodiment shown in FIGS. 11 a and b depicts body 90 inthe unfolded position. This embodiment comprises body portions 92, 94having a thickness such that hinge portion 96 is provided adjacentdepressions 98, 100 on the surface body portions 92, 94, respectively.Because body 90 is a unitary body, the flexibility of hinge portion 96is derived from forming same into a relatively thin member, as hereindiscussed below. In such folding situations as shown in FIG. 12 a,material adjacent the hinge may interfere with the body's ability tofold completely. These depressions 98, 100 allow body portions 92, 94 tofold as shown in FIG. 12 a, without material from said body portionsinterfering therewith. As shown in FIG. 12 b, a cavity 102 is formedwhen body portions 92, 94 are folded completely. It is contemplated,however, that such occasions may arise wherein it may not be desired toremove such material adjacent hinge portion 96, as depicted withdepressions 98, 100. Such instances are contemplated to be within thescope of this disclosure.

In the illustrative embodiment shown in FIG. 11 b, hinge portion 96forms an arcuate path between body portions 92, 94. The radii assists inremoving a dimple that may occur at the hinge when the hinge is at about180 degrees of bend. As shown in FIG. 12 b, hinge portion 96 loses someof its arcuate shape when the body portions 92, 94 are in the foldedposition. It is appreciated, however, that such a hinge 96 is notlimited to the arcuate shape shown in FIG. 11 a. Rather, hinge portion96 may be any shape so long as it facilitates relative movement betweentwo connecting body portions. For example, hinge portion 96 may belinear shaped. The shape of the hinge portion may also be influenced bythe size and shape of the body portions, as well as the desired amountof movement between said body portions.

Illustratively, in addition to, or in lieu of, the fibrous materialforming the visor hinge via high pressure alone, the hinge may also beformed by having a band of material removed at the hinge area. In oneillustrative embodiment, a hinge having a band width about ⅛ inch wideand a removal depth of about 70 weight percent of thickness mass allowsthe hinge full compression thickness after molding of about 0.03125inch, for example. The convex molding of the hinge may straighten duringfinal folding assembly, providing a straight mid line edge between thetwo final radiuses. It is contemplated that the mold for the mirrordepressions, etc., plus additional surface molding details can beachieved using this process. It is further anticipated that the coverstock may be applied during the molding process where the cover isbonded to the visor by the polypropylene contained in the fibrousmaterial formulation.

The illustrative embodiment of body 90 includes longitudinally-extendingdepressions 93, 95 which form a cavity 97. (See FIGS. 11 a, 12 a and 14a.) Cavity 97 is configured to receive bar 99, as discussed furtherherein. (See FIG. 14 b.) It is appreciated that such depressions andcavities described herein with respect to body 90 are for illustrativepurposes. It is contemplated that any design requiring such a moldablebody and hinge can be accomplished pursuant the present disclosureherein.

As previously discussed, body 90 may be comprised of low densitymaterial to allow variable forming geometry in the visor structure,i.e., high and low compression zones for allowing pattern forming. Forexample, the panels portion may be a low compression zone, whereas thehinge portion is a high compression zone. In addition, the highcompression zone may have material removed illustratively by a saw cutduring production, if required, as also previously discussed. Thisallows for a thinner high compression zone which facilitates the abilityfor the material to be flexed back and forth without fatiguing, usefulfor such a hinge portion.

An end view of a die assembly 110 for compression molding a fibermaterial body and hinge is shown in FIG. 13. The form of the dieassembly 110 shown is of an illustrative shape. It is contemplated thatsuch a body 90 can be formed into any desired shape. In the illustratedembodiment, assembly 110 comprises illustrative press plates 112, 114.Illustratively, dies 116, 118 are attached to plates 112, 114,respectively. Die 116 is formed to mirror corresponding portion of body90. It is appreciated that because the view of FIG. 13 is an end view,the dies can be longitudinally-extending to any desired length. Thisillustrative embodiment of die 116 includes surfaces 120, 122 andincludes compression zones 124, 126, 128, 130. Zones 124, 126 areillustratively protrusions that help form the depressions 93, 95,respectively, of body 90, as shown. (See also FIG. 11 a.) Zones 128, 130are illustratively protrusions that help form the depressions 98, 100,respectively, of body 90, as shown. (See also FIG. 11 a.) And zone 132is illustratively a form that, in cooperation with zone 134 of die 118,form hinge portion 96.

This illustrative embodiment of die 118 includes surfaces 136, 138 andincludes compression zones 140, 142, 134. Zones 140, 142 areillustratively sloped walls that help form zone 134. (See also FIG. 11a.) Zone 134 is illustratively a peak that, in cooperation with zone 132creates a high compression zone to form hinge portion 96, and,illustratively, depressions 98, 100, if desired. Again, it isappreciated that the present pattern of such zones shown is not the onlysuch pattern contemplated by this disclosure.

In the illustrated embodiment, body 90, in the illustrative form of ahinged visor, is folded as that shown in FIG. 12 a. It is furthercontemplated that during forming the body may be heated by hot air tobring it up to forming temperatures. The heating cycle time may be about32 seconds, and the toll time after clamp for cool down will be around45 to 50 seconds, depending on tool temperature. Furthermore, skins,like a fabric skin can be bonded to the visor during this step.

Another embodiment of the hardboard panel is a low density panel,illustratively, an approximately 2600 gram panel with about 50 weightpercent fiber-like hemp, kenaf, or other fiber material with about 50weight percent polypropylene. Such materials are subjected to hot air toproduce a light-weight, low density panel. The panel material may beneedle-punched or have a stretched skin surface applied thereon for useas a tackable panel, wall board, ceiling tile, or interior panel-likestructure.

A portion of a dry-erase board 150 is shown in FIG. 15. Such a board 150may comprise a hardboard panel 152 (similar to panel 2) pursuant theforegoing description along with a surface coating 154. The surfacecoating, as that described further herein, provides an optimum worksurface as a dry-erase board. Surface coating 154, for example, can be aClass A finish previously described. This illustrative embodimentincludes a frame portion 156 to enhance the aesthetics of board 150. Oneembodiment may comprise a dual-sided board with a low density tack boardon one side and a dry-erase hardboard on the other side.

An illustrative embodiment of a work body in the form of a table top180, is shown in FIG. 16. The view illustrated therein is a partialcut-away view showing the mating of a top 182 to an underside 184. Anillustrative pedestal 186 supports table top 180 in a conventionalmanner. It is appreciated, however, that the table top 180 is shown inan exaggerated view relative to pedestal 186 so as to better illustratethe relevant detail of the table top 180.

In the illustrated embodiment, the periphery 188 of top 182 is arcuatelyformed to create a work surface edging. The top 182 is attached to theunderside 184 via a portion of the periphery 190 of the same mating withthe top 182. Periphery 190 illustratively comprises an arcuate edgeportion 192 which is complimentarily shaped to the interior surface 194of periphery 188 of top 182. Adjacent the arcuate edge portion 192 is anillustrative stepped portion 196. Stepped portion 196 provides a notch198 by extending the underside panel 202 of the underside 184 downwardwith respect to top 182. Notch 198 provides spacing for edge 200 ofperiphery 188. Such an arrangement provides an appearance of a generallyflush transition between top 182 and underside 184. Interior surface 194of periphery 188 and outer surface 204 of periphery 190 can be mated andattached via any conventional method. For example, the surfaces can beionize-charged to relax the polypropylene so that an adhesive can bondthe structures. In addition, a moisture-activated adhesive can be usedto bond the top 182 with the underside 184.

Detailed views of the mating of top 182 and underside 184 is shown inFIGS. 17 and 18. The conformity between peripheries 188 and 190 isevident from these views. Such allows sufficient bonding between top 182and underside 184. The generally flush appearance between the transitionof top 182 and underside 184 is evident as well through these views. Thevariations between illustrative embodiments are depicted in FIGS. 17 and18. For example, top surface 206 is substantially coaxial with levelplane 208 in FIG. 17, whereas top surface 206 is angled with respect tolevel plane 208. It is appreciated, as well, that the disclosure is notintended to be limited to the shapes depicted in the drawings. Rather,other complimentarily-shaped mating surfaces that produce such atransition between such top and bottom panels are contemplated to bewithin the scope of the invention herein.

Such mating of top 182 and underside 184 may produce a cavity 210, asshown in FIGS. 16 through 19. Depending on the application, cavity 210may remain empty, or may contain a structure. For example, FIG. 19 showsan end view of table top 180 with a truss member core support 76illustratively located therein. Truss member core 76 can be of the typepreviously described and be attached to the interior surfaces 194, 212via conventional means, such as an adhesive, for example. Such a corestructure can provide increased strength to table top 180. In fact, suchstrength can expand the uses of the work body to other applications inaddition to a table top. For example, such can be used as a flooring, orside paneling for a structure or a vehicle. It is contemplated thatother such cores can be used in place of the truss member. For example,a foam core or honeycomb core can be used in place of the truss.

An illustrative hardboard manufacturing line 300 is shown in FIGS. 20through 28. Line 300 is for manufacturing laminated hardboard panels ofthe type shown in FIGS. 1 through 3, and indicated by reference numeral2, for example. The manufacturing process comprises the mating of theseveral layers of materials, illustratively layers 6 and 8 (see FIG. 1),heating and pressing said layers into a single laminated compositepanel, cooling the panel, and then trimming same. In the illustrativeembodiment, line 300 comprises the following primary stages: uncoilingand mating 302 (FIG. 22), pre-heating 304 (FIG. 23), heat and press 306(FIG. 24), cooling 308 (also FIG. 24), laminating station (FIGS. 25through 28), and shear and trim 310 (also FIGS. 25 through 28.) A topview of line 300 is shown in FIG. 21. It is appreciated that the line300 may be of a width that corresponds to a desired width of thecomposite material. FIG. 21 also illustrates the tandem arrangement ofeach of the stages 302, 304, 306, 308, 310.

The uncoiling and mating stage 302 is shown in FIG. 22. In theillustrative embodiment, the materials used for forming the compositeare provided in rolls. It is appreciated that the materials may besupplied in another manner, but for purposes of the illustratedembodiment, the material will be depicted as rolls. Illustratively,stage 302 holds rolls of each illustrative layer 6 and 8 in preparationfor mating. As illustrated, stage 302 comprises a plurality of troughs312 through 320, each of which being illustratively capable of holdingtwo rolls, a primary roll and a back-up roll, for example. In oneembodiment, it is contemplated that any number of troughs can be used,and such number may be dependent on the number of layers used in thelaminated body.

For this illustrative embodiment, line 300 is configured to manufacturea laminated composite panel 2 similar to that shown in FIGS. 1 through3. It is appreciated, however, that the utility of line 302 is notlimited to making only that panel. Rather, such a line is also capableof manufacturing any laminated panel that requires at least one of thestages as described further herein. Troughs 312, 316, and 320 eachcomprise a primary roll 6′ and a back-up roll 6″ of layer 6. In thisexample, layer 6 is illustratively a non-oriented fibrous material.Similarly, troughs 314 and 318 each comprise a primary roll 8′ and aback-up roll 8″ of layer 8 which is illustratively the woven fiberlayer. Each roll rests on a platform system 322 which comprises a sensor324 and a stitching device 326. Sensor 324 detects the end of one rollto initiate the feed of the back-up roll. This allows the rolls tocreate one large continuous sheet. For example, once fibrous materialprimary roll 6′ is completely consumed by line 302, and sensor 324detects the end of that primary roll 6′ and causes the beginning ofback-up roll 6″ to join the end of primary roll 6′. This same processworks with primary roll 8′ and back-up roll 8″ as well.

To secure each roll of a particular material together, stitching device326 stitches, for example, the end of primary rolls 6′ or 8′ with thebeginning of the back-up rolls 6″ or 8″, respectively. The stitchedrolls produce a secure bond between primary rolls 6′, 8′ and back-uprolls 6″ and 8″, respectively, thereby forming the single continuousroll. Illustratively, stitching device 326 trims and loop stitches theends of the materials to form the continuous sheet. Also,illustratively, the thread used to stitch the rolls together is madefrom polypropylene or other similar material that can partially meltduring the heating stages, thereby creating a high joint bond in thefinal panel. It is contemplated, however, any suitable threads can beused which may or may not be of a polymer.

Each trough of stage 302 is configured such that, as the material isdrawn from the rolls, each will form one of the layers of the laminatedcomposite which ultimately becomes the hardboard panel. Fibrous materiallayer 6 of primary roll 6′ from trough 312 illustratively forms the toplayer with the material from each successive trough 314 through 320,providing alternating layers of layers 6 and 8 layering underneath, asshown exiting at 321 in FIG. 22. Each roll of material is illustrativelydrawn underneath the troughs exiting in direction 327. The resultinglayered materials exit stage 302 at 321, pass over bridge 328, and enterthe pre-heating stage 304.

Pre-heat stage 304, as shown in FIG. 23, comprises an oven 323 whichforces hot air at approximately 240 degrees F. into the compositelayers. Oven 323 comprises a heater-blower 330 which directs heated airinto composite chamber 332 which receives the material layers. This hotair removes moisture from layers 6, 8, as well as heats the center-mostlayers of the same. Because often such materials are hydrophobic, theremoval of the moisture causes the center of the materials to cool. Theforced heat causes the center to be warmed, even while the moisture isbeing removed.

This pre-heat allows the process to become more efficient during theheat and press stage 306. Stage 308 illustratively comprises aroller/belt system which includes rollers 333 that move belts 335, asshown in FIG. 23. Illustratively, these belts are located above andbelow the panel 2, defining at least a portion of chamber 332. Belts 335assist in urging panel 2 through stage 304 and on to stage 306.

The preheated composite layers exit through opening 334 of stage 304 andenter the heat and press stage 306, as shown in FIG. 24. The pre-heatedcomposite panel 2 enters stage 306 through opening 336 and into chamber337. The heat and press stage 306 uses a progression of increasinglynarrowly-spaced rollers located between heat zones, thereby reducing thevertical spacing in chamber 337. The combination of the heat and thenarrowing rollers reduces the thickness of panel 2 transforming sameinto a laminated composite panel 2 of desired thickness. For example,stage 306 comprises pairs of spaced rollers 338, 340, 342, 344, 346, 348through which the composite layers pass. The rollers are linearly spacedapart as shown in FIG. 24. In one illustrative embodiment, to make a 4millimeter panel, rollers 338 will initially be spaced apart about 15millimeters. Successively, rollers 340 will be spaced apart about 12millimeters, rollers 342 will be spaced apart about 9 millimeters,rollers 344 will be space apart about 6 millimeters, and finally,rollers 346 and 348 will be each spaced apart about 4 millimeters. Thisgradual progression of pressure reduces stress on the rollers, as wellas the belts 350, 352 driving the rollers. Such belts 350, 352 generallydefine the top and bottom of chamber 337 through which panel 2 travels.Because of the less stress that is applied to belts 350 and 352 whichdrive rollers 338, 340, 342, 344, 346, 348, such belts 350, 352 can bemade from such materials as Teflon glass, rather than conventionalmaterials such as a metal. The Teflon belts absorb less heat than metalbelts do, so more of the heat generated will be transferred to the tothe lamination of panel 2, in contrast to production lines usingconventional metal belts. In one illustrative embodiment, stages 306 and308 are approximately 10 meters long and approximately 4 meters wide.

In one illustrative embodiment, located between every two pairs ofrollers is a pair of surfaces or platens 354, 356 between which thepanel 2 moves during the lamination process. Illustratively, platens354, 356 receive hot oil or similar fluid. It is appreciated, however,that other methods of heating the platens can be used. In the presentembodiment, however, the hot oil causes the platens 354, 356 to raisethe core temperature of the panel 2 to about 340 degrees F. Thecombination of the compression force generated by the rollers 338, 340,342, 344, 346, 348 and the heat generated by the platens 354, 356 causesthe polypropylene in the material layers 6, 8 to melt, causing same tobegin fusing and compacting into the panel 2 of desired thickness.

After the layers 6, 8 of the composite panel 2 is heated, fused, andreduced to a desired thickness, the resulting composite panel 2 iscooled at cooling stage 308. In the illustrated embodiment, coolingstage 308 is an extension of the heat and press stage 306 to the extentthat stage 308 also includes pairs of rollers 358, 360, 362, 364, 366which are similarly situated to, and arranged linearly with, rollers338, 340, 342, 344, 346, 348. The space between each of the rollers isabout the same as the space between the last pair of rollers of the heatand press stage 306, in this case rollers 348. In the forgoing example,the rollers 348 were illustratively spaced apart about 4 millimeters.Accordingly, the spacing between the rollers of each pair of rollers358, 360, 362, 364, 366 of stage 308, through which the panel passes, isalso spaced apart about 4 millimeters. Cooling stage 308 treats platens372 through 406 that are cooled with cold water, illustratively atapproximately 52 degrees F., rather than being treated with hot oil, asis the case with heat and press stage 306. This cooling stage rapidlysolidifies the melted polypropylene, thereby producing a rigid laminatedhardboard panel 2.

Hardboard panel 2 exits the cooling stage 308 at exit 408, as shown inFIG. 24, and enters the shear and trim stage 310, as shown in FIGS. 25through 28. In one illustrative embodiment, composite panel 2 passesthrough an interior wall laminating stage 410 and into the trim andcutting stage 412. When panel 2 passes through stage 412, its edges canbe trimmed to a desired width and the panel cut to any desired lengthwith the panel exiting to platform 414.

A top view of line 300 is shown in FIG. 21 which includes the variousaforementioned stages 302, 304, 306, 308, 310 as well as finishing astage 416. This stage 416 is illustratively for applying an acrylic orother like resin finish to the surface of the composite panel.Specifically, once such a composite panel 2 exits the shear and trimstage 310, it is supported on a plurality of rollers 418 and placedalong the length of platform 414 to move panel 2 in direction 420. Inone illustrative embodiment, panel 2 may be rotated into position, asshown in FIG. 28, to finishing stage 416. To rotate panel 2, movablecatches 422, 424, one at the proximal end of platform 414 and the otherat the distal end of platform 414, as shown in FIGS. 21 and 28, bothmove concurrently to move panel 2. Catch 422 moves a corner of panel 2in direction 420 while catch 424 moves the other corner of panel 2 indirection 426, ultimately positioning panel 2 on platform 415 at stage416. It is appreciated, however, that it is not required to locate sucha finishing stage at an angle relative to line 300. Alternatively, stage416 may be located linearly with the remainder of line 300.

Illustratively, before applying the acrylic finish to panel 2 at stage416, its surface is first prepared. The illustrative process forpreparing the surface of panel 2 is first sanding the surface to acceptthe finish coat. After sanding the surface of panel 2, a wet coating ofthe resin is applied. Illustratively, the resin is polyurethane. Theacrylic resin can then be UV cured, if necessary. Such curing iscontemplated to take as much as 24 hours, if necessary. Initial cooling,however, can take only three seconds. Such an acrylic coating hasseveral uses, one is the dry-erase board surface, previously discussed,as well as exterior side wall panels for recreational vehicles and pulltype trailers. It is further contemplated herein that other surfacecoatings can be applied at stage 416 as known by those skilled in theart.

In another illustrative embodiment, interior wall laminating stage 410,though part of line 300, can be used to create wall panel compositesfrom panel 2. When making such panel, rather than panel 2 passingthrough stage 410, as previously discussed, panel 2 is laminated atstage 410. In this illustrative embodiment, as shown in FIGS. 25 and 26,for example, stage 412 comprises an uncoiling hopper 430, a hot airblower 432, and a roller stage 434. Hopper 430 is configured to supportillustratively two rolls of material. For this illustrative embodiment,a base substrate layer 436, and a finish surface material layer 438 islocated in hopper 430. It is appreciated that the base substrate layer436 can be any suitable material, including the fibrous material layer 6as previously discussed or a priming surface material. The finishsurface material layer 438 can be of any finishing or surface materialsuch as vinyl, paper, acrylic, or fabric.

Uncoiling hopper 430 operates similar to that of stage 302 to the extentthat they both uncoil rolls of material. Hopper 430 operates differentlyfrom stage 302, however, to the extent that both layers 436 and 438uncoil concurrently, rather than in tandem, like rolls 6′ and 6″, forexample. In other words, both layers 436, 438 will form the layers ofthe composite top coat, rather than form a single continuous layer for aboard, as is the case with roll 6′and 6″.

In the illustrative embodiment, base substrate layer 436 uncoils belowthe finish surface material layer 438, as shown in FIGS. 26 and 27. Inaddition, layers 436 and 438 form a composite as they enter roller stage434. The hot air blower 432 blows hot air 448 at approximately 450degrees F. in direction 448 between layer 436 and layer 438. This causesthe surfaces, particularly the base material layer 436 surface, to melt.For example, if the base substrate layer 436 is fibrous material layer6, the polypropylene on the surface of this material melts. As layer 436and layer 438 pass between a pair of rollers 450 at the roller stage434, the melted polypropylene of layer 436 bonds with the layer 438,forming a composite of fibrous material having the finish surfacematerial 438. After the materials have formed a laminated composite,they can then proceed to the shear and trim stage 310.

It is contemplated that finish surface material layer 438 may compriseseveral finish materials applied to base material layer 436 eitherconcurrently or in tandem. For example, a roll of material layer 438 maycomprise a roll that includes a section of vinyl, attached to a sectionof paper, and then fabric, and then vinyl again.

Uncoiling this roll and bonding it to layer 436 produces a singlecomposite board having several tandemly positioned finish surfaces thatcan be sheared and cut at stage 310 as desired.

Another illustrative hardboard manufacturing line 500 is shown in FIGS.29 and 30. Line 500 is another embodiment for manufacturing laminatedhardboard panels of the type illustratively shown in FIGS. 4 through 6.This manufacturing line 500 is similar to manufacturing line 300previously discussed, wherein process 500 comprises the mating ofseveral layers of materials, illustratively layers 22, 24, as well asthe calendaring surface 32 and coated surface 34, as shownillustratively in panel 30 of FIG. 6. Manufacturing line 500 comprisesthe following panel manufacturing stages: the uncoiling and matingstages 502, the pre-heating stage 504, the heat and press stage 506, thecooling stage 508, the calendaring stage 510, and the shear and trimstage 512.

One illustrative embodiment of line 500 comprises a calendaring stage510. This stage is located in the same location as the laminating stage410 of line 300, as shown in FIG. 25. The purpose of the calendaringstage is to smooth the top surface of the illustrative panel 30 toprepare it for the paint application of line 514.

Conventionally, using belts 350, 352 in conjunction with the heatedplatens may cause the texture of those belts, similar to a clothpattern, to be embedded in the surfaces of the panel 30. (See, also,FIG. 24.) The calendaring process removes this pattern to provide asmoother surface in anticipation of the paint application. In theillustrated embodiment shown in FIG. 30, calendaring stage 510 comprisesa conveying line 570 and spaced apart rollers 572, as well as a heatsource 574. As panel 30 exits the cooling stage 508, it is transferredto the calendaring stage 510 where the heat source, illustrativelyinfrared heat or heated air, or a combination of both, is applied to thesurface of the panel 30. Panel 30 is then directed between the twospaced apart rollers 572 which will then smooth the surface that hasbeen heated by heater 574. In one embodiment, it is contemplated that atleast one of the rollers is temperature controlled, illustratively withwater, to maintain the rollers up to an approximate 120 degrees F. It isfurther contemplated that the heated air or IR heater is controlled toonly heat the surface of panel 30 and not the center of the boarditself. Furthermore, it is contemplated that the roller can subject upto an approximate 270 pounds per linear inch force on the surface of thepanel 30 in order to smooth out any pattern in the surface and/orrelated defects thereon to produce a calendared surface 32 as previouslydiscussed with respect to FIG. 6. It will be appreciated that thiscalendaring process will prepare the surface 32 of panel 30 so that itmay receive a Class A auto finish. Once the panel 30 exits thecalendaring stage 510, it then is transferred to the shear and trimstage 512 where the panel will take its final shape prior to the paintstage.

In contrast to manufacturing line 300, however, line 500 furthercomprises paint application line 514. Paint line 514 comprises atransfer conveyer 516 which moves panels, in this illustrative casepanel 30, from the shear and trim stage 512 to the paint line 514. Thisis accomplished illustratively by rollers on conveyer 518 moving panel30 perpendicularly from shear and trim stage 512 to paint line 514 whichis illustratively positioned parallel to line 500. If, for example,panel 30 or the other panels 20 and 28 do not receive a paintapplication, they can be removed from the line at an off-load point 520.If panel 30, for example, will be receiving a paint application, it isloaded onto paint line 514 via a staging section 522 as shown in FIG.29. The first stage of the paint process of paint line 514 is to flametreat the top surface of panel 30 at 524. The flame treatment process isa means to relax the surface tension and ionize-charge the board forchemical bonding. This will decrease the surface tension of the plasticor the bonding material. Such decrease in surface tension allows theplastic to have a similar surface tension to that of the paint that willcreate better adhesion of the paint to the board. In the illustrativeembodiment, the flame treatment uses a blue flame approximately ¼ inchin height, and the board is passed below the flame of about ⅜ of an inchat a rate of about 26 feet per minute. It is appreciated, however, thatother means of heating the surface of panel 30 is contemplated and, inregards to the flame size, temperature, and the distance of the boardfrom the flame, is illustrative and not considered to be the soleembodiment of this disclosure.

It is contemplated that much of the paint line will be enclosed and,because of such, after the flame treatment stage 524, an air inputsection is added to create positive pressure within the line. In theillustrative embodiment, a fan is added to this section to input airwhich will blow dust and debris away from the panel to keep it clean.The next stage of paint line 514 is the adhesion promoter spray booth528. Booth 528 applies a plastic primer to the surface of panel 30 thatintegrates with the plastic in the board to assist in better adhesion ofsubsequent paint layers. In this illustrative embodiment, a down-draftspray of the primer is applied to the surface of panel 30.

Exiting booth 528, another air input section 530 is illustrativelylocated to further create positive pressure to continue preventing dustor other contaminates from resting on the surface of the panel.

After panel 30 exits the adhesion promoter booth 528, it enters the UVprimer seal spray booth 532. Booth 532 applies a UV filler paint tofurther level the surface of the panel 30, as well as serve as anadditional primer for the final UV care paint. It is appreciated,however, that depending on the application of the panel, the UV fillercan be replaced with a UV paint or other paint as a topcoat. In thisillustrative embodiment, however, the booth 532 uses a down-draft sprayto apply the primer seal onto panel 30.

Exiting booth 528, panel 30 then enters an ambient flash stage 534wherein the panel 30 rests to allow solvents from the paint toevaporate. Though not shown, the solvents are drawn from the ambientflash stage 534 where the solvents are burned so as to not enter theatmosphere. In addition, stage 534 may include an input fan 536, similarto air inputs 526 and 530, to maintain positive pressure in thissection.

After allowing the solvents to dissipate from the surface of the panel30, it is transported under a UV cure lamp 538 to further cure thepaint. The UV cure 538 is illustratively a high-intensity, ultra-violetlight to which the paint is sensitive, and which will further cure thepaint.

After passing through UV cure 538, the panel 30 is passed through aninfrared oven 540. The panel 30 is moved through oven 540 at anillustrative rate of 2.5 meters per minute and the IR oven is set atabout 165 degrees F. This step further assists to drive out anyremaining solvents that might not have been driven out prior to the UVcure. In addition, those solvents are also then sent off and burnedbefore reaching the atmosphere.

Once exiting the IR oven 540, panel 30 is transferred to a side transfersection 542 which allows either removal of panel 30 if the paint appliedat booth 532 was the final application of paint, or through conveyors544 as shown in FIG. 29, if panel 30 is to be transferred to a secondarypaint line 546.

If panel 30 is transferred to secondary paint line 546, it is passedthrough another spray booth 548. Booth 548 uses a down-draft spray toapply a UV topcoat over top the UV filler and adhesion promoter coatspreviously discussed. The UV topcoat will be the finished coat thatprovides the Class A auto finish as previously discussed, for example.Once the topcoat has been applied onto the surface of panel 30, thefollowing process is similar to that as described with respect to paintline 514 which is that the panel 30 is again subjected to an ambientflash at section 550, similar to ambient flash stage 534 previouslydiscussed, wherein the solvents are allowed to evaporate, and are drivenoff and burned. Furthermore, the panel is transferred through a UV cure552 section, similar to that of 538 and as previously discussed, the UVcure 552 serves also as UV high-intensity light to further cure thetopcoat applied at 548. After passing through the UV section 552, panel30 then enters infrared oven 554, which is similar to IR oven 540previously discussed, wherein the panel is subjected to a temperature ofabout 165 degrees F. for about 2.5 minutes.

When panel 30 exits the IR oven, it enters an inspection booth 556 wherethe surface is inspected for defects in the paint or in the board. Theinspection can be either manually accomplished by visual inspection ofthe surface and identifying such defects, or can be accomplished throughan automated inspection process comprising sensors to locate defects,etc. In addition, the inspection booth 556 also serves as a cool-downprocess for the process. The inspection booth 556 maintains atemperature of about 78 degrees F. with about 50 weight percent relativehumidity to cool down at least the surface of the board from theapproximate 165 degrees F. from the IR oven to about 80 degrees F. If aboard does not pass inspection, it will be removed for repair orrecycling.

If the board does pass inspection, it will pass through a pinch roller558 that will apply a slip sheet which is illustratively a thin 4millimeter polypropylene sheet that protects the painted surface ofpanel 30 and allow the same to be stacked at the off-load section 560.

Composite materials, like those used to manufacture automobile bodiesand interiors, have the potential to be recycled into new materials. Animpediment to such recycling, however, is incompatible particle sizes ofotherwise potentially recyclable constituents. For example, a variety ofcombinations of polypropylene, vinyl, polyester, ABS, and fibrousmaterials may be used to produce a panel or core product for a panel.

In the recycle system 600, shown in FIGS. 31 through 33, severalmaterials are collected and segregated based on a desired composition at602. Each material is granulated to reduce its particle size. The degreeto which each material is granulated can be varied depending on thechemistry desired in the resulting panel. After each material isgranulated, the loss and weight is determined at 604. This is done sothat the cross-section and weight can be controlled before the resultantmaterial is laminated into a panel. The materials are blended into acomposition at 606 and transferred to collector 608. The composition isthen transferred from collector 608 through a metal detector 612 whichis configured to remove metal particles. The remaining composition isthen deposited into a scatter box 614. Scatter box 614 allows particlesof a particular maximum size to deposit onto granulate belt 616. Theloss and weight of the resulting composition is then determined again tomaintain the density of the final panel. The composition is thentransferred to the recycle composition storage 626 in anticipation fordeposit with the other laminate constituents.

The recycled composition manufacturing panel line 618, shown in FIGS. 32and 33, is similar to line 300 shown in FIG. 20. Line 618 comprises thefollowing primary stages: uncoiling 620, pre-heater 622, heat andpressure 624, recycled material storage 626, cooling 628, shear and trim630. In the illustrated embodiment of FIG. 32, rolls 632, 634 ofmaterial, such as a fibrous or woven glass material, for example, arelocated at stage 620. Rolls 632, 634 are uncoiled to form compositelayers. These layers are then pre-warmed using pre-heater stage 622,similar to stage 304 used in manufacturing line 300. The recycledcomposition material from stage 626 exists in the form of chips havingan irregular shape with a maximum dimension in any one direction of,illustratively, 0.125 inches, and is then deposited between thecomposite layers. The new composite layers are then subjected to thesame heat, pressure, and cooling at stages 624 and 628, respectively, asto the heat and press stage 306 and the cooling stage 308 ofmanufacturing line 300.

The heat and pressure stage 624 receives the preheated composite layers,and through a progression of increasingly narrowly-spaced rollers,compresses the composite layers to a desired thickness similar to thatpreviously discussed. Again, this gradual progression of pressurereduces stress on the rollers and the belts driving the rollers, asdiscussed with stage 306 of line 300. In addition, the belts that drivethe rollers can, too, be made of Teflon glass material, rather than ametal, also previously discussed.

Also similar to stage 308, stage 628 includes a pair of surfaces orplatens between every two pairs of rollers to allow the composite layerto move there between. Illustratively, the platens receive hot oil. Itis appreciated that other methods of heating the platens arecontemplated, similar to stage 306. After the composite layers areheated, fused, and reduced to a desired thickness, the resulting panelis cooled. Cooling stage 628 is comparable to stage 308. The final stageis shear and trim 630, which is also similar to the shear and trim stage310 of line 300.

As shown in FIGS. 32 and 33, line 618 further includes a dual sidelamination stage 636. Stage 636 is similar to stage 410, shown in FIG.25, except for the additional uncoiling stage 638 located beneath aprimary uncoiling stage 637. It is contemplated that applying a surfaceon both sides of a composite panel is the same as applying a singlesurface, as shown in FIG. 20, with the exception that warm air will bedirected to both sides of the composite panel. The process as shown inFIG. 20 does apply to the lower surface as well.

A sectional view of fibrous substitute material layer 6 is shown inFIGS. 36 a through c. The distinction between the views of FIGS. 36 athrough c is the amount of heat and pressure applied to fibrous materiallayer 6. As previously discussed above, fibrous material layer 6illustratively comprises a mat of illustratively about 25 weight percenthemp and about 25 weight percent kenaf with the balance beingillustratively polypropylene. The fibers are randomly oriented toprovide a nonspecific orientation of strength. Variations of thisfibrous material are contemplated, including an about 24.75 weightpercent hemp and about 24.75 weight percent kenaf combination with about50 weight percent polypropylene and about 0.05 weight percent maleicanhydride. Other such fibrous materials can be used as well, such asflax and jute, for example. It is also contemplated that other blendratios of the fibrous material can be used. It is further contemplatedthat other binders in place of polypropylene may also be used for thepurpose discussed further herein. Still further, it is contemplated thatother fibrous materials which have high process temperatures in excessof about 400 degrees F., for example, may be used as well.

The fibrous material layer 6 shown in FIG. 36 a is considered a virginversion of the layer, similar to that shown in FIG. 1, or on rolls 6′and 6″ shown in FIG. 22. This version of layer 6 is considered virgin,because it has not been subjected to a heat treatment or was compressed.The fibers and the binder that compose the layer exist as essentiallyseparate constituents simply mixed together. In this state, the virginversion is highly permeable and pliable. The relative thickness 700 ofthe layer 6 is relatively greater than the thicknesses 702 or 704 oflayers 6 shown in either FIGS. 7 b and 7 c, respectively. Furthermore,because the binder, polypropylene, for example, is not bound to thefiber, heating layer 6 may cause it to consolidate or shrink,particularly in its length and width.

In contrast, layer 6 shown in FIG. 36 c, though comprising the sameconstituents as layer 6 in FIG. 36 a, has been subjected considerably toheat and pressure. This embodiment of layer 6 is considered a highdensity version. In this case, the binder has been fully wetted-out.Fully wetted-out, for the purposes of this discussion means that thebinder has, for practical purposes, all liquefied and bonded to thefibrous material of layer 6. Such produces an essentially non-permeable,dense and rigid body. The binder, typically a thermal melt polymer, likepolypropylene, is melted into a liquid state, causing the polymers toadhere to and/or wet-out the fibrous materials. This can produce aconsolidation of the composite when cooled which shrinks the layer. Thisresults, however, in a rigid and dimensionally stable flat sheet. Ifsuch a layer is then reheated, because the binder is already bonded withthe fibrous material, the layer will not shrink, unlike the layer 6described in FIG. 36 a. Such high density layers are used to produce thelayers 72, 74 of truss composite 70, previously discussed with respectto FIG. 10, for example.

The version of layer 6 shown in FIG. 36 b, in contrast to both thevirgin and high density versions from FIGS. 36 a and c, respectively, isconsidered a low density version. This low density version has beensubjected to heat and pressure, so that a portion of the binder in thelayer has been wetted-out, unlike the virgin version of FIG. 36 a whichhas not been subjected to such a process. Furthermore, unlike the highdensity layer shown in FIG. 36 c, the binder of the low density layerhas not been fully wetted-out.

In other words, not all of the binder in the low density layer hasliquefied and bonded to the natural fibers, only a portion of the binderhas. The remaining binder is still maintained separate from the fibrousmaterial. This makes the low density version rigid, similar to the highdensity version, yet, also semi-permeable, more akin to the virginversion. In one illustrative embodiment, the binder has melted andsoaked into about 50 percent of the fibers that are in the layer. Inthis case, it is not believed that the fibers per se have grown, norchanged in a specific value. Rather, the fibers have just absorbed thebinder.

The low density version can provide accelerated processing forthree-dimensional molding, particularly in molding, like that shown inFIGS. 11 and 12, where various compression zones are used to form thematerial. Furthermore, utilizing such a composite provides lowerproduction costs. In addition, because the layer is rigid, yet has somepermeability, it can be used as a tack board alone or in conjunctionwith the dry erase board 150 of FIG. 15, for example. The propertiesalso make it conducive to acoustical insulation or ceiling tiles.

Conventional heat sources such as infra red ovens are not used to heat ahigh density layer 6 material, because it may cause changes to itsphysical dimensions or cause overheating of the surface area of the highdensity layer 6 in order to bring the core up to proper processingtemperatures. In contrast, contact heating ovens, which use upper andlower heated platens to hold a virgin layer 6 under pressure duringheating to prevent significant shrinkage, are not readily available inthe general molding industry that may use such materials. Furthermore,the target cycle times required to heat these layers to moldingtemperatures require extra energy and equipment.

Using the low density version of layer 6 can, on balance, be a more costeffective way to mold such fibrous material layers. For example, an 1800gram per meter square sample of fibrous material, as described withrespect to FIGS. 26 a through c, may require about 83 seconds of heattime in a contact oven to get the virgin version up to moldingtemperature. The high density version may require 48 seconds of heattime in an IR oven. The low density board, however, may require onlyabout 28 seconds of heat time in an air circulated hot air oven. This isto reach a core temperature of about 340 to 350 degrees F.

When heating the low density version in a simple air circulated hot airoven, the energy required to heat low density board is 50 percent lessthan the required energy to heat the layer through a contact oven and 70percent less than the required energy to heat a consolidated hard boardutilizing infra red oven. The high density layer is typically onlyheated by an infrared oven. This is because the high density versiondoes not have the permeability for hot air, and contact ovens mayoverheat and damage the layer.

Some benefits of the high density version over the virgin version arealso found in the low density version. First of all, similar to how thehigh density version requires less packaging space than the virginbecause of its reduced thickness, the low density version too requiresless packaging space since its thickness is also less than that of thevirgin version. Such translates into reduced shipping costs. Secondly,because the low density version is rigid, like the high density version,the low density version can be handled much easier with mechanicaldevices, such as grippers and clamps. This can be more difficult withthe virgin version which is more pliable. Also, the low density materialdoes not always have to be pre-heated. Some applications of the virginversion may require the layer to be preheated so as to dimensionallystabilize the material. This is not necessary with the low densityversion. In contrast, for those production lines that use a needlesystem to handle materials, particularly, for materials like the virginversion of layer 6, the high density version would not receive suchneedles, because of the solidified binder. The low density version,however, still being semi-permeable, may receive such needles, allowingit to be transported easily, similar to that of the virgin version.

Manufacture of the low density version like that shown in FIG. 36 ccomprises subjecting the virgin version to both heat and pressure. Theheat and pressure is illustratively provided by an oven which comprisescompressed rolls that pinch the material to reduce its ability to shrinkwhile it is being heated. The rolls have belts with holes disposedtherethrough, through which the hot air passes. The layer is being heldas structurally rigid as possible so it does not suck-in and becomenarrow and thick in the middle. The heat and pressure causes the binderto liquefy, and under the rollers, causes the melted binder to beabsorbed into and surround the natural fiber. The layer may shrink tosome minor extent, but that can be compensated for during thismanufacturing process. When the layer is removed from the oven, cold airis blown on it to solidify the layer.

Typically, thermal melt polymers are heat sensitive, and at temperaturesabove 240 degrees F. will attempt to shrink (deform). Therefore, theopposing air permeable belts having opposing pressures limits the amountof heat sink shrinkage that will occur during this process. Once theinitial heating has occurred (polymers changed from a solid to liquidstate), and consolidation of thermal melt and non-thermal melt fibersare achieved, the consolidated layer 6 becomes thermal dimensionallystable. After heating, and while the consolidated mat is undercompression between the opposing air permeable belts, the layer ischilled by ambient air being applied equally on opposite sides of theconsolidated mat to, again, bring the thermal melt polymers back to asolid state.

Additional embodiments of the present disclosure comprise structuralmats and resulting panels that in one embodiment have heat deflectioncharacteristics, in another embodiment have high strengthcharacteristics, and in another embodiment have heat deflection and highstrength characteristics. It is appreciated that the heatdeflection/high strength characteristics are exhibited in the panel formof the structural mat. It is further appreciated that the percentagesdisclosed herein are percentages by weight.

A first illustrative embodiment is a nucleated polypropylene compositionwherein the nucleated material is an amorphous aluminosilicate glass.The nucleated polypropylene can be added to natural or synthetic fibersto form a structural panel. In one illustrative embodiment approximately1% nucleate material is added to the polypropylene content. An exampleof such an aluminosilicate glass nucleate material is sold under thetrade name Vitrolite® by the NPA Corporation. The Vitrolite(I may reducethe molecule size of the polypropylene, and may, thus, increase heatdeflection of the panels by approximately 15% and 20%. The Vitrolite(may also substantially improve the impact strength of the panel andmoderately improve its flexural or tensile strengths. The impactstrength (amount of applied energy to sample failure) may increasebetween 25% to 50% over non-nucleated formulations of same type andweights. It is appreciated that other nucleate agents can be used hereinin alternative embodiments.

An example of such improvements can be seen when comparing two equalformulations of same gram weight, type of base polypropylene used insame percentage of formulation and same percentage and type of naturalfiber. The only difference in formulation in test, sample 2 contains 1%nucleate additive in the formulation polypropylene content. Sample 1contains no nucleate additive, but includes all other substrates inexact portions and types. Both formulations tested contained 50%polypropylene and 50% natural fiber. Samples were prepared using aconventional carding/cross lapping process whereby the materials werehomogenously blended into a composite sheet. Their results are asfollows: Samples: 1. Standard 2. Nucleated Flexural Modulus 248,000 psi330,000 psi Tensile Strength 3,065 psi 3,550 psi Heat Deflection @ 66psi 156 Celsius 169 Celsius Impact Energy 3.00 in-lbf 4.00 in-lbf

Assembled data is based on 10 sample run per production lot number.There were three lot numbers run, for a total of 30 samples. Thepercentage of material types in formulation can vary from about 40%nucleated polypropylene with about 60% natural fiber up to about 60%nucleated polypropylene with about 40% natural fibers.

Formulations outside the upper and lower percentage blend limits are notbelieved practical since they may not provide any enhanced material orapplication value.

Another illustrative embodiment is a fiber mat comprising a couplingagent, such as maleic anhydride in solution. For example, anillustrative composition may comprise approximately 7% maleic anhydridecontent in solution added to approximately 50% polypropylene andapproximately 50% natural fiber blend. The polymer blended rate ofapplication is approximately 4% coupling agent with approximately 96%polypropylene material. The 7% maleic anhydride content of the couplingagent improves both polymer grafting and surface bonding between polymerand natural fiber, which may double the strength of the panel. Anillustrative example of such material is sold under the trade nameOptipak 210® by the Honeywell Corporation. The maleic anhydride mayimprove polymer grafting and surface bonding between polar and nonpolarmaterials and, thus, may increase the overall mechanical strengths ofthe panels by approximately 75% and 100%. It is appreciated that othercoupling agents may also be used. This formulation in combination withthe fiber material forms the panel, pursuant means further discussedherein. It is further appreciated that the material can be natural orsynthetic fibers and be randomly oriented or woven.

An example of such improvements can be seen by comparing two equalformulations of same gram weight, type of base polypropylene used insame percentage of formulation and in same percentage and type ofnatural fiber. The only difference in formulation between the samples isthat sample 2 contains 4% maleic coupling additive in formulationpolypropylene content. Sample 1 contains no coupling additive, butincludes all other substrates in exact portions and types. Bothformulations tested contained 50% polypropylene and 50% natural fiber.Samples were prepared using a conventional carding/cross lapping processwhereby the materials were homogenously blended into a composite sheet.Their results are as follows: Samples: 1. Standard 2. Coupled FlexuralModulus 248,000 psi 450,500 psi Tensile Strength 3,065 psi 7,750 psiHeat Deflection @ 66 psi 156 Celsius 161 Celsius Impact Energy 3.00in-lbf 1.75 in-lbf

Assembled data is based on 10 sample run per production lot number.There were three lot numbers run, for a total of 30 samples. Thepercentage of material types in formulation can vary from approximately40% coupled polypropylene with approximately 60% natural fiber up toapproximately 60% coupled polypropylene with approximately 40% naturalfibers.

Another illustrative embodiment comprises a combination ofnucleated/binder material and the coupled/binder material blended with afibrous material to for a structural mat that forms a heatdeflection/high strength panel. Illustratively, the combination ofVitrolite® as the nucleating agent and Optipak 210® as the couplingagent can create a high strength/high heat deflection panel.

An illustrative embodiment comprises approximately 4% of the couplingagent and approximately 1% of the nucleating agent in full compositeblend. To achieve this blend, the formulation is made up ofapproximately 25% nucleated polypropylene with approximately 2%Vitrolite(& additive and approximately 25% coupled polypropylene withapproximately 8% Optipak 210® additive. The balance is approximately 50%natural fiber. The constituents are combined and spun to form a 2%nucleated polymer fiber, with an 8% coupled polymer fiber mixed withnatural fiber (and/or synthetic fiber), either woven or random, to forma high temperature deflection, high strength and impact resistant mat orboard. The combined formulation preserves some of the heat deflectionand strength achieved independently by the nucleated and coupledcompositions.

An example of such improvements can be seen by comparing three equalformulations of same gram weight, type of base polypropylene used insame percentage of formulation and in same percentage and type ofnatural fiber. The only difference in formulation between the samples isthat sample 1 contains 1% nucleate additive in formulation polypropylenecontent, sample 2 contains 4% coupled additive in formulationpolypropylene content, and sample 3 contains a blend of 1% nucleateadditive polypropylene at 25% of total blend and 4% coupled additive at25% of total blend. All 3 formulations tested contained 50%polypropylene and 50% natural fiber. Samples were prepared using aconventional carding/cross lapping process whereby the materials werehomogenously blended into a composite sheet. Their results are asfollows: Samples: 1. Nucleated 2. Coupled 3. Combined Flexural 330,000psi 450,500 psi 410,000 psi Modulus Tensile 3,550 psi 7,750 psi 5,450psi Strength Heat 169 Celsius 161 Celsius 164 Celsius Deflection @ 66psi Impact 4.00 in-lbf 1.75 in-lbf 3.10 in-lbf Energy

As these results demonstrate, the combined panel (Sample 3) exhibits aflexural modulus and tensile strength comparable to the coupled panel.The combined panel also exhibits heat deflection and impact strengthcomparable to nucleated panel. The results demonstrate thatcharacteristics of both a nucleated/binder fiber panel and acoupled/binder fiber panel can be present in a combined nucleated/binderand coupled/binder panel. The results show that the combined sample hascoupled and nucleated properties that are not as pronounced as theindividual samples. This may be due to the fact that less coupling andnucleating agents are used in the combined sample than individualsamples.

Illustratively, achieving full values of mechanical strength, heatdeflection and full offset of negative impact strength due to thecoupling agent includes a formulation comprising approximately 25%percent polypropylene with approximately 2% nucleate additive,approximately 25% polypropylene with approximately 8% coupling additivecombined with approximately 50% natural fiber. Other formulationscontaining any ratio up to the maximum additive of approximately 2%nucleate and approximately 8% coupled provide both mechanical strength,impact strength and heat deflection improvements when compared tostandard formulation of equal blend that contain no nucleate/coupledcombined or nucleate or coupled singular.

Percentage of material types in formulation can very from approximately40% nucleate/coupled polypropylene with approximately 60% natural fiberup to approximately 60% nucleate coupled polypropylene withapproximately 40% natural fibers.

Another benefit of such a panel can be in total reduction in mass weightto meet application strength and performance requirements. For example,an 1800 gram per meter square (gsm) composite application to meetspecific data requirements may be reduced to 1200 gsm in total weightand still meet the same data requirements. This may translate intoapproximately a 33% material weight reduction and provide further costbenefits either in composite or in end use such as reduction in partweight, which in turn provides reduced vehicle weight resulting inpossibly improved fuel mileage and reduced cost to operate on a per milebase over the life of the vehicle. It is also notable that the couplingof the fiber may improve grafting strength between polar and nonpolarsubstrates being synthetic fibers such as polypropylene or polyestersand natural fibers such as hemp, jute, kenaf, tossa and other such likefibers. The maleic anhydride acid serves this function. It may breakdown the non-polymer fiber surfaces to allow surface impregnation ofpolymer when it is in liquid state. It is further noted that naturalfiber, glass, other types of fibers or flexible materials, either wovenor unwoven, can be used.

An illustrative manufacturing process for the structural matcompositions comprise adding the aluminosilicate glass and maleicanhydride to polypropylene pellets to form polypropylene fibers. In thiscase, however, the nucleated polypropylene fibers are made whollyseparate from the coupled polypropylene fibers. It is appreciated thatadding both a nucleating agent and a coupling agent together to thepolypropylene in a single system will not work. It had been found thatadding both nucleating and coupling agents to polypropylene to form thefibers causes the polymer chains to break because the polypropylenecould not accept so much additive. Several attempts were made to combineboth a nucleate agent and a coupling agent with polypropylene for fiberproduction. The combination of material upset the molecular weight ofthe polymer reducing the liquid viscosity to a point that continuousfiber filament productions was not possible.

Consequently, two separate systems are created, as illustratively shownin FIG. 37. This chart shows the illustrative process of making astructural mat hardboard panel 800. The process comprises making thepolypropylene fibers as indicated by reference numeral 802,manufacturing a fibrous mat as indicated by reference numeral 804, andmanufacturing the panel as indicated by reference numeral 806. The firstblending system 808 makes the nucleated polypropylene fibers. Herepolypropylene pellets 810 and the nucleating agent (e.g.,aluminosilicate glass) 812 are combined at 814, extruded at 816, spun at818, drawn and spinfinished at 820, and crimped and cut into nucleatedpolypropylene fibers at 822 of conventional size used in structuralfiber mats. Similarly, second blending system at 824 makes the maleic orcoupled polypropylene fibers. Here polypropylene pellets 826 and thecoupling agent (e.g., maleic anhydride) at 828 are combined at 830,extruded at 832, spun at 834, drawn and spinfinished at 836, and crimpedand cut into nucleated polypropylene fibers at 838 of conventional sizeused in structural fiber mats.

In this illustrative embodiment, about 4% of the nucleated polypropylenefiber from system 808 is the aluminosilicate glass with the balancebeing polypropylene. In system 824, about 16% of the coupledpolypropylene fiber is the coupling agent, maleic anhydride, with thebalance being polypropylene. In the illustrated embodiment, a blend ofabout 25% discreet nucleated polypropylene and 25% discreet coupledpolypropylene is added to bast fiber to begin forming the structuralmat.

A non-woven structural mat is formed at 804 pursuant methods discussedat least partially above and known to those skilled in the art. The bastfiber is blended with the nucleated/coupled polypropylene at 840. Thenon-woven structural mat can then be trimmed and cut as desired at 842.It is appreciated that during the blending process at 840, a generallyhomogeneous blend of the nucleated polypropylene and coupledpolypropylene occurs.

Once the mats are formed, they are available for three-dimensionalmolding to form a hardboard panel or molded structure at 806. Asillustratively shown, and as at least in part previously discussed, aswell as known to those skilled in the art, the structural mat is raisedto melt temperature of the polypropylene at 844 and either compressedinto a flat panel or molded into a three-dimensional shape at 846. Theresulting panel exhibits the high heat deflection and strength, asindicated at 846. It is believed that during thermal processing, thehomogenous blend of maleic polypropylene fibers and nucleatedpolypropylene fibers flow together when in full melt stage allowing themolecules of each to combine, creating a unique combined chemistry thatis not believed possible using conventional extrusion methodology.

Although the present disclosure has been described with reference toparticular means, materials and embodiments, from the foregoingdescription, one skilled in the art can easily ascertain the essentialcharacteristics of the present disclosure and various changes andmodifications may be made to adapt the various uses and characteristicswithout departing from the spirit and scope of the present invention asset forth in the following claims.

1. A structural mat for manufacturing a moldable structural hardboardpanel, the structural mat comprising: a nucleated/coupled bindermaterial comprising: a first binder material combined with a nucleatingagent; a second binder material combined with a coupling agent; whereinthe first binder material combined with the nucleating agent makes adiscrete nucleated/binder material and the second binder materialcombined with the coupling agent makes a discrete coupled/bindermaterial; and wherein the discrete nucleated/binder material and thediscrete coupled/binder material are blended together; and a fibrousmaterial blended with the discrete nucleated/binder material and thediscrete coupled/binder material, and formed into the structural mat. 2.The structural mat of claim 1, wherein the first and second bindermaterials are each polypropylene, and wherein both the discretenucleated/binder material and the discrete coupled/binder material arein fibrous form.
 3. The structural mat of claim 2, wherein the firstbinder material combined with the nucleating agent further comprisesabout 4% nucleating agent with the balance being the first bindermaterial;
 4. The structural mat of claim 2, wherein the second bindermaterial combined with the coupling agent further comprises about 5%coupling agent with the balance being the first binder material.
 5. Thestructural mat of claim 2, further comprising about 25% discretenucleated/binder material.
 6. The structural mat of claim 5, furthercomprising about 25% discrete coupled/binder material.
 7. The structuralmat of claim 6, further comprising about 50% fibrous material.
 8. Thestructural mat of claim 2, further comprising about 25% discretenucleated/binder material with about 2% of the structural mat being thenucleating agent, about 25% discrete coupled/binder material with about2.5% of the structural mat being the coupling agent, and about 50%fibrous material.
 9. The structural mat of claim 2, wherein thenucleating agent is an aluminosilicate glass.
 10. The structural mat ofclaim 9, wherein the coupling agent is maleic anhydride.
 11. Thestructural mat of claim 2, wherein discrete nucleated/binder materialand the discrete coupled/binder material are blended homogeneously. 12.The structural mat of claim 2, wherein the fibrous material is arandomly-oriented fibrous material.
 13. The structural mat of claim 12,wherein the randomly-oriented fibrous material is a natural fibermaterial.
 14. The structural mat of claim 2, wherein the fibrousmaterial is a woven material.
 15. A structural panel having highstrength and high heat deflection properties, said panel comprising arigid body comprised of solidified nucleated/coupled binder material andfibrous material, each dispersed throughout the thickness of the body;wherein the solidified nucleated/coupled binder is formulated from anucleated material with a binder and a coupled material with a binder.16. The structural panel of claim 15, wherein the nucleated/coupledbinder material comprises polypropylene.
 17. The structural panel ofclaim 16, further comprising about 50% nucleated/coupled polypropylenewhich comprises about 4% nucleating agent and about 5% coupling agent,and about 50% fibrous material.
 18. The structural panel of claim 15,wherein the nucleating agent is an aluminosilicate glass.
 19. Thestructural panel of claim 15, wherein the coupling agent is maleicanhydride.
 20. The structural panel of claim 15, wherein the fibrousmaterial is a randomly-oriented fibrous material.
 21. The structuralpanel of claim 15, wherein the randomly-oriented fibrous material is anatural fiber material.
 22. The structural panel of claim 15, whereinthe fibrous material is a woven material.
 23. The structural panel ofclaim 15, wherein the nucleated/coupled polypropylene is in aconcentration from about 40% to 50%.
 24. The structural panel of claim23, wherein the fibrous material is in a concentration from about 50% to60%.
 25. A method of making a structural mat for manufacturing amoldable structural hardboard panel, the method comprising the steps of:combining a nucleating agent with a first polypropylene material;forming a solid fibrous combination of nucleating agent and firstpolypropylene material; combining a coupling agent with a secondpolypropylene material, separate from the blended nucleating agent andfirst polypropylene material; forming a solid fibrous combination ofcoupling agent and second polypropylene material; blending the solidfibrous combination of nucleating agent and first polypropylene materialwith the solid fibrous combination of coupling agent and secondpolypropylene material; blending a fiber material with the blended solidfibrous combination of nucleating agent and first polypropylene materialand solid fibrous combination of coupling agent and second polypropylenematerial; and forming a structural mat by combination of the fibermaterial with blended solid fibrous combination of nucleating agent andfirst polypropylene material and solid fibrous combination of couplingagent and second polypropylene material.
 26. The method of claim 25,further comprising the step of formulating the nucleating agent andfirst polypropylene material with about 4% nucleating agent and thebalance being the first polypropylene material.
 27. The method of claim26, further comprising the step of formulating the coupling agent andsecond polypropylene material with about 5% coupling agent and thebalance being the second polypropylene material.
 28. The method of claim27, further comprising the step of providing about 25% nucleating agentand first polypropylene material.
 29. The method of claim 28, furthercomprising the step of providing about 25% coupling agent and secondpolypropylene material.
 30. The method of claim 29, further comprisingthe step of providing about 50% fibrous material.
 31. The method ofclaim 25, further comprising the step of providing about 25% nucleatingagent and first polypropylene material with about 2% of the structuralmat being the nucleating agent, about 2.5% coupling agent and secondpolypropylene material with about 4% of the structural mat being thecoupling agent, and about 50% fibrous material.
 32. The method of claim25, further comprising the step of blending the nucleating agent andfirst polypropylene material and the coupling agent and secondpolypropylene material homogeneously.
 33. The method of claim 25,further comprising the step of providing the nucleating agent and firstpolypropylene material and the coupling agent and second polypropylenematerial in a concentration from about 40% to 50%.
 34. The method ofclaim 33, further comprising the step of providing the fibrous materialin a concentration from about 50% to 60%.
 35. The method of claim 25,further comprising the steps of: heating the structural mat to at leastthe melt temperature of the first and second polypropylene material;asserting pressure to the structural mat; and forming a hardboard bodyfrom the mat.